Networked communications system and segment addressable communications assembly box, cable and controller

ABSTRACT

A communication systems providing a fault-tolerant communications path for narrow and broad band communication comprising one or more self-powered satellite units each providing signal information to at least one command console through a segmented cable assembly system in operable communication with a central station that receives signal information from the at least one command console and relays signal information back to the command console wirelessly and via the segmented cable assembly system.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.12/021,076 filed Jan. 28, 2008, which claims the benefit for priorityfrom U.S. Provisional Application No. 60/886,905 filed Jan. 26, 2007,both applications of which are hereby incorporated herein by referencein their entirety.

BACKGROUND OF THE INVENTION

The inventions described relate generally to a networked communicationssystem. More particularly, the inventions herein relate to a faulttolerant intra-communications and inter-communications systems andassemblies thereof.

Most, if not all, cable systems used in communications and powerindustries are designed to comply with a single function, that beingeither power or communications. And when it comes to different modes ofpower or communications components have been designed separately andindependently; few if any can truly integrated with other components,Connectivity standards of such components are also not designed towithstand damage (e.g., fire or mechanical problems). As such, currentsystems are unreliable and do not function or remain operational underadverse conditions.

SUMMARY OF THE INVENTION

The inventions described herein solve many problems associated withcurrent communications systems

Generally, and in one form, is provided a networked communicationssystem for narrow and broad band signal communication, the systemoperable with a segment addressable communications assembly (SACA)junction box and cable for terrestrial and wireless communication thatis fault tolerant.

Those skilled in the art will further appreciate the above-notedfeatures and advantages of the invention together with other importantaspects thereof upon reading the detailed description that follows inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For more complete understanding of the features and advantages of thepresent invention, reference is now made to the detailed description ofthe invention along with the accompanying figures, wherein:

FIG. 1A depicts in schematic a networked communications systems andrepresentative transmission pathways as described herein;

FIGS. 1B and 1C depict a flow chart of representative communicationspaths as described herein;

FIG. 2A depicts in cross-section a schematic of a representative cableassembly as described herein;

FIG. 2B depicts a representative fabricated cable assembly as describedherein;

FIG. 2C depicts a blow-out view of the cable assembly of FIG. 2A;

FIG. 2D depicts a detail view of the loop of the cable assembly of FIG.2C;

FIG. 3 depicts in schematic form a first view of a SACA cable assemblyand junction box;

FIG. 4 depicts in schematic form a second view of a SACA cable assemblyand junction box;

FIG. 5 depicts in schematic form a second view of a SACA cable assemblyand junction box;

FIG. 6 depicts in schematic form a plan view of the exterior of ajunction box;

FIG. 7 depicts a representation of a typical cable race tray describedherein;

FIGS. 8A and 8B depict various views of junction box circuitry;

FIG. 9 depicts a representative drawing of a controller system case anddesign;

FIG. 10 illustrates by representation a depiction of a communicationssystem and circuitry as described herein;

FIG. 11 depicts a representative improved antenna as described herein;and

FIG. 12 depicts an image of a media converter described herein.

DETAILED DESCRIPTION OF THE INVENTION

Although making and using various embodiments of the present inventionare discussed in detail below, it should be appreciated that the presentinvention provides many inventive concepts that may be embodied in awide variety of contexts. The specific aspects and embodiments discussedherein are merely illustrative of ways to make and use the invention,and do not limit the scope of the invention.

In the description which follows like parts may be marked throughout thespecification and drawing with the same reference numerals,respectively. The drawing figures are not necessarily to scale andcertain features may be shown exaggerated in scale or in somewhatgeneralized or schematic form in the interest of clarity andconciseness.

This application is being filed concurrently with co-pending U.S. patentapplications, each of which claims the benefit for priority from U.S.Provisional Application No. 60/886,905 filed Jan. 26, 2007, and eachdescribing aspects of the invention described herein, including GIMBALEDMOUNT SYSTEM FOR SATELLITES (U.S. patent application Ser. No.12/020,269), NETWORKED COMMUNICATIONS AND EARLY WARNING SYSTEMS, andSECURITY ASSEMBLY AND SYSTEM.

The communications system as described herein includes an integratedsatellite based device capable of broadband digital signaling, thedevice is also referred to herein as satellite unit (SU). Each SU isable to be in constant alignment with a desired satellite. The satellitedish itself may be round or elliptical and mounted, generally in avertical orientation, parallel to the horizontal plane. The mount may bea gimbaled mounting system, motorized, and/or self-aligning. Preferably,the satellite is self-powered and self-contained and comprises a dishassembly, a self-stabilizing mount, and a controller section containinga transceiver for wireless communication. A transceiver, as describedherein, is operational at variable power levels and wavelengths andcompliant with public local area network (LAN) use (e.g., IEEE/ITU802.15.4) and emergency/military use (e.g., IEEE/ITU 802.15.3). An SUhaving a transceiver, typically a radio frequency transceiver, iscoupled with Ultra Wide Band (UWB) technology to re-broadcastinformation to other receivers.

Further included with a system described herein is a custom cableassembly also referred to as a segment addressable communicationsassembly (herein “SACA”) cable system or a terrestrial link. In oneform, a SACA cable system allows one or more SUs to become operable witha command console. A SACA cable system may offer both vertical andhorizontal integration of information to a command console.

A command console may be located anywhere, preferably in a positionconsidered safe, such as a building, shelter, emergency operationcenter, disaster coordination center, emergency dispatch center. inanother preferred embodiment, the command console is positioned separateand apart from a safe location and while positioned independently isstill in operational communication with such safe locations. In thelatter design, a command console initiates communication with the safelocation via a broadband connection through the SU satellite. A commandconsole also has interconnectivity with any public data or voice networkthrough digital bridging. Thus, a command console may also initiatecommunication with any public data or voice network via digitalbridging.

Command console-initiated communication is provided through one or anumber of sites, including a central monitor and/or one or moredetectors. Control of the SU transceiver is also under the command ofthe central monitor via software. Thus, the SU provides a fault tolerantbroadband satellite link that is also integrated with other components.

Each command console offers interconnectivity via a network with one ormore SUs (10 as depicted in FIG. 1A). As such, a central monitor 20connects one or more SUs 10 with one or more receiving units 30, whichincludes safe locations, homes, offices and other network locations. Acentral monitor may also be in operable communication with a detector40. A schematic representation of one representation of a communicationssystem described herein is illustrated in FIG. 1A and described furtherbelow. A flow chart of representative communications pathways possiblewith a communications system described herein is shown in FIG. 1B

Detectors include sensors (remote controlled or otherwise and includesensors for, e.g., radiation, chemical, bio-hazard, explosive, seismic,heat, pressure). One or more detectors may be associated with an SU.

The communications system described herein is further provided with anelectrical power source. Each power source is interfaced at a commandcenter using existing wiring and/or a remote data acquisition system. Apower source provides a means for interconnectivity to sensors and/orfor relaying other information, such as audible information in the formof alerts or sirens. A robust power supply system with multiple powersource supplies provides uninterruptible operation should there be anyfault in part of the system or an emergency even in which one or moreconventional power sources are negated. A power source may be also bemaintained at the central monitor.

As described herein, a communications system includes in part or inwhole one or a number of SUs at one or a number of locations withcommand centers and a central monitor. The communications system may actas an alert, warning, control or monitoring system. Informationcommunicated though the communications system may be relayed to one of anumber of ports, including computer, landline telephone, cellular phone,PDA, lighting unit, and mechanical system (e.g., via a Web page-enabledmanager), as examples.

A command console generally includes hardware, its own un-interruptiblepower supply (UPS) power supply, a routing box, and another transceiveras depicted on the lower right in FIG. 10 as 1010. One or more UPS powereach command console. A command console serves as a secondary powersource to an SU. Cabling between an SU and the command console isthrough a SACA cable assembly system 1020, which includes an armoredmechanically and thermally protected cable having sectionallyaddressable access points (shown in FIGS. 2A-2C). In one form, a SACAcable assembly system may be used as a tunable antennae system dependingon its location (e.g., within a building having diverse locations). Acommand console is, therefore, capable of interconnecting with abuilding and with a pre-wired system.

Additionally or as an alternative, further links may be installed in thecommand console using UWB technology (e.g., IEEE/ITU 802.15.4/UWB). Suchadded bridge components may be installed at a remote location within anequipped SU to relay signals to the command console, an example isdepicted as 1030 in FIG. 10. This prevents additional wiring and offersenhanced reliability to the system.

In one communication relay pathway, a central monitor providesinformation to a command console located in a building that is receivedfrom a service provider (e.g., environmental, security, facilitiesmanagement, utilities). The information is generally received wirelesslyand via a direct connection to the equipped building. Again, a schematicand a generalized flow chart of some representative communicationspathways as described herein are depicted in FIGS. 1A and 1B,respectively. Services such as private network devices and Voice overInternet Protocol (VoIP) may be supplied wirelessly using thecommunications systems described herein. An equipped building may alsoact as a relay station by way of its transceiver to provide broadbandre-direct-able connections to other sites equipped to receive thecommunication. This provides an abundant number of resources forcommunicating information.

Connectivity through a SACA cable relies on a SACA junction box having arepeater system to extend a wireless communications range (e.g., WiFiIEEE/ITU 802.11a/b/g addressable repeater system), as exemplified inFIGS. 3, 5 and 8A. SACA cables serve to address connectivity between anSU and a command console. In addition, SACA cables have output ports atvarious lengths along the segments for periodic and/or separatelyaddressable sections to re-broadcast a signal (e.g., digital UWB, WiFi,RF) that has been injected by a provided connector at a command console.

The SACA cable system is custom constructed in one or more fixed lengthsegments to match requirements of an end installation. For example, 10,20 100 and 300 foot lengths are obtainable. The cable system may bereadily expanded or reduced as needed to enhance fiber opticconnectivity. Power management components are determined by end powerrequirement needs. Cable stress release may be adjusted based on size ofinternal stress of the member installed. A typical configuration of acable assembly is for 2600 pounds of longitudinal force. There are novertical or horizontal structural constraints when using the SAGA cablesystem described herein. Components of the SACA cable system comply withand exceed UL standards, meet and exceed UL Circuit Integrity (CI)compliance requirements and are deemed Fire Hardened Integrity Tested(FHIT),

A cross-sectional view of a cable assembly is depicted in FIG. 2A. Theexterior casing 10 is of spiral metal construction and generally made ofa high gauge steel (e.g.; #14) or aluminum. The casing is typicallyflexible, resistant to high mechanical forces, has an interlocking wrap(e.g., RWS type). Suitable examples include BX or type AC flexible steelcable. Preferably the casing is 1 inch thick and is of the highest gaugemetal available for a chosen cable assembly diameter. Standard casingshave no coating. As an alternative a coating may be applied to thecasing as described further below. The interior includes a core bundle15 comprising one or number of power conductors 20, multi-modefiber-optic data channels 30, coaxial cable 40 and high strength stresscable, in a desired combination, all of which are encircled in theirentirety with a flexible heat resistant silica aerogel wrap 50. The wrapis suitably reinforced, generally with a non-woven, carbon and/or glassfiber batting. A suitable blanket material may be found with Pyrogel®(Aspen Aerogels, Inc., Northborough, Mass.). Typically, the wrap isapplied in a 50% overlapping 6 mm spiral wrap over the entire interiorcontents. As such, the wrap is continuous and extends uninterrupted overthe entire length of each cable segment (as measured from end to end).

At each end of a cable segment, core bundle 60 that includes theflexible heat resistant wrap extends further than casing 10 asexemplified in FIG. 2C. At each segment end 65, the casing is clampedwith a cable clamp 66, typically installed with a lockout 67 andsilicone ring as exemplified in FIG. 3. End clamps are compression fitusing non-flammable seating rings on both external mounting threads aswells an approved silicone sealing ring on the cable compression nutfitting. A loose lead extension at each end of the core bundle istypically about 26 inches longer than the casing. The length may varyand is enough to ensure strain-less connection to a terminus box ateither end of the cable segment. At an end of each core bundle is amulti-conductor connector 70 (FIG. 2A and inset FIG. 2C; also shown inFIG. 2B). The connector is terminated by a loop that extends about sixinches from the end marked as 75. The loop is generally a standard ¼inch loop 80. Fiber optic channels are terminated with appropriate plugsor other suitable terminations. A suitable plug is exemplified with aVolition™ connector system (3M Corporation, St. Paul, Minn.). The lengthof a cable segment is defined by the distance from one connector facingside to the other connector facing side.

Examples of representative cable assemblies include 20 and 300 footlength segments (SA.CA-T), a lite 300 foot length cable (SAGA-lite) and20 and 300 foot water proof cables (SACA-W). For SACA-T, the core bundlewas linear wrapped with 4 mil thick aerogel. The casing was bareflexible steel clad apical wrapped. The core bundle included 3×2conductor PNR multi-mode fiber optic cables, an RG-188 AU coaxialhigh-temperature cable, and 3×10 AWG/19ST B/W/G multi-core power leads.For SACA-lite, the core bundle was linear wrapped with 4 mil thickaerogel. The casing was bare flexible steel clad apical wrapped. Thecore bundle included 3×2 conductor PNR multi-mode fiber optic cablesprepared as a loose laced wrapped bundle, an RG-188 AU coaxialhigh-temperature (200 degree-rated) cable, 3×10 AWG/19ST B/W/Gmulti-core 200 degree-rated power leads and a CAT-6 cabling, plenumgrade. For SACA-W, the core bundle was linear wrapped with 4 mil thickaerogel. The casing was flexible steel clad apical wrapped with aplastic water proof coating. The core bundle included 3×2 conductor PNRmulti-mode fiber optic cables, an RG-188 AU coaxial high-temperaturecable and 3×10 AWG/19ST B/W/G multi-core 200 degree-rated power leads.

For terminations of leads in each core bundle, the aerogel extended 1inch minimum beyond the casing end. Leads extending beyond the aerogelwrap were at least 22 inches before proper termination. Power leads had½ inch bare copper ends. Fiber optic lines were polarizationnon-reciprocity (PNR) and terminated with male plugs. The coaxial cablewas terminated with a male plug. Ethernet cabling was CAT-6 terminatedin an RJ-45 connector A fitting.

One method for preparing the cable assembly described herein includesapplying the casing around the core bundle after the core bundle isassembled. An alternative method is to stuff a prepared core bundle intoa desired casing. With either process, mechanical wrapping of the bundleis done with a near zero air gap to the bundle from the inner walls ofthe fabricated outer casing, while maintaining an industry standard sizeat the beginning and length of each cable segment. The casing isgenerally provided in one of a number of fixed industry diameter sizes.Typical coil rings are set for overlapping that creates a minimum of 11rings per foot, thereby maximizing lateral force protection fromentering or damaging the core bundle. Using a standard cable sizes, eachcore bundle (including the flexible heat resistant wrap) is no largerthan 60-70% of the interior diameter of a flexible casing sizespecification. Optionally, the cable assembly may include providing awater tight or water repellent layer around the perimeter of the outercasing.

As described herein, by using a heavier gauge outer casing than isconventionally used and combined with a tighter than normal ring spacingand a steel non-flammable compression fitting for termination, the cableassembly herein is much improved, being both stronger and more thermallyprotected than conventional assemblies described by others.

Referring now to the core bundle, bundling of each core begins withhaving specifications being met as provided by the desired number ofoptical channels as well as desired power handling requirements for anindividual cable segment. The choice of components combined with theaddition of a longitudinal strain relief system (SRS) determines aprimary core bundle size prior to wrapping.

The power conducting cable will have an outer protected sheath ofthermally enhanced plastic around copper wires. The outer sheath may bethermally enhanced or further coated with such a material, an example ofwhich is Teflon® (E.I. du Pont de Nemours and Company), either of whichensures high thermal protection in a heated environment. The number ofstrands of copper wire is 26 or more, which is higher than a usual lowerindustry standard of six or seven strands. As such, power conducingcables described herein have a combined current carrying capacity thatis about 30% higher than standard multi-strand copper conducts.

A coaxial cable for data (wireless) communication is generally in theform of a 50-ohm or 75-ohm coax cable with suitable insulation. Anexample is an RG-188 A/U standard cable. The cable should handle RFinterconnects; however, HF, VHF and UHF may also be useful.

A fiber component for data handling is typically in the form of amulti-mode fiber. Use of a multi-mode fiber offers more reliability thana single mode fiber in the event of any thermal and/or mechanical damageto the cable segment. The preferred fiber is a 62.5 or 50.0 microndiameter multi-mode fiber and has a long-chain polyimide coating(housing), which is preferably a fluoropolyimide (e.g., aramid) thatoffers high resistance to heat and melt. Each fiber has a fiber jacketwith an overall dimension at or about 12.5 microns in diameter. Thefibers are inserted in the jacket with or without a silicone buffertube. The outer jacket is also of thermally enhanced plastic to resisthigh temperatures and be considered flameproof. The outer jacket ensuresthat long term cable heating will have a negligible effect on datahandling capacity of the fibers.

Generally, the fiber component may be single or paired with up to sixchannels. When possible, fibers are minimized to reduce heat and enhancethermal resistance of the core bundle. The fibers are generallyterminated with a raceway tray, as required. In one example, terminationof a multi-mode fiber optic pair includes a duplex fiber opticinterconnect plug, exemplified by a Volition™ connector system (3MCorporation, St. Paul, Minn.). An interconnect plug is preferred to afused butt joint as signal loss per connector is reduced. Termination ismade with strict compliance to requirements to ensure maximum signalstrength and minimal signal loss. A selected plug (or joint) is alwayscompatible with the mating socket or equivalent optical transceiver onthe junction box. For example, a Volition™ connector system is matedwith a Volition™ socket.

When more than 6 fiber channels are required, they are routed within acable race tray and individually thermally bonded to the next cablesection for all pass through connections. Drop point circuits to thejunction box site are thermally bonded to pre-manufactured patch cordsper specifications, allowing about 26 inches from a cable race tray exitpoint. An alternate fiber connector when multi-stranded fibers is toprovide a dual termination set-up using a splice and then a patch cordto individual channels. Such termination is readily combinable with aSACA junction box described herein.

Having a combination of both high power conducting lines and opticalfibers for highest and longest broadband transmission, the cableassembly described herein surpasses assemblies described by others. TheSACA assembly uses multiple strands, typically three Amerimay wire gauge(AWG) #10 multi-strand wires. Cable ends are ½ inch bare wire, tinnedfinished.

To counter longitudinal force applied to cable assemblies describedherein, an SRS system is further provided in each core bundle beforewrapping. The SRS system comprises a high strength cable (e.g.,2100-2600 pound test [load] strength, 5×9 or 1×19, 19 strand steel ⅛ to5/32 inch diameter cable) inserted in the internal core bundle. The SRScable has a high melt point, which may be at or about or greater than1800 degrees Fahrenheit. The ends are finished in a loop (FIG. 2A, 2B),looping 6 inches from the clamp fitting facing surface. This providesadequate length to slip over a strain relief stud mounted inside a SACAjunction box. With proper anchoring termination aligned to be 6 incheslonger than the cable assembly specified length at either ends andfabricated to attach to a mating stud anchoring point in the middle ofthe side wall of the junction box, the SKS system transfers longitudinalforces whether direct or from lateral displacement of the SACA cableassembly from the cable to the corresponding mounting stud on thejunction box (see, e.g., FIG. 3 and FIG. 4). The SRS component withinthe SACA cable assembly prevents damage from occurring to the wirecables or delicate fiber optic lines and ensures there is no decouplingor stretching of the outer flexible casing.

High thermal temperatures associated with fires and the like willregularly damage so-called fire hardened or plenum rated cables becausethe thermal boundary or protection level in that is in such cables hasno relevance to the actual energy level present in a typicalcarbon-based fire. To overcome fire damage, the final assembly step incore bundling (after assembly of the SRS system) is wrapping the corebundle with a predetermined width band of an aerogel material,Preferably, wrapping is performed by spiral wrapping in a 50%overlapping configuration. Wrapping covers the entire length of the corebundle and occurs prior to applying the reverse-wrapped interlockingcasing.

An addressable junction box with mating multi-conductor cable plugs actas the junction device for the SACA cable. Details of the SACA junctionbox are now discussed and depicted in FIGS. 3-5, 8 and 10. In general,the SACA junction box is a multi-function junction box. It serves as atap out point for signal repeating, it is also a power junction pointand link out from one section to a next section. Each segmented lengthof cable is combined with a repeater (via the junction box) and, thus,the historical maximum application length of 3000 feet is not an issuewith the cable assembly described herein. A dual WAN router withwireless connectivity eliminates the need for a separate WiFi router andcan be mounted on a mezzanine board.

Custom boxes may include one down stream feeder and one or multipleupstream branches. An example would for use with a multi-story structurehaving multiple sections off a single core. In such a case, each SACAjunction box would be typically located about 10-20 feet apartvertically and have branched boxes on each floor of the structure, inwhich each box in a horizontal distance would be about 500 feet or moreapart. Similarly, a set-up may be provided in subterranean or enclosedenvironment (e.g., mined locations, subway, caves, tunnels, asexamples).

Housing for a SACA junction box is depicted in FIG. 6, and is generallymade of a heavy gauge metal and water tight box thermally protected fromoutside heat by having all walls lined with a non-conductive layer usinga water repellent material, such as an aerogel. The metal is preferably#14 gauge, as a minimum, and preferably steel. Generally, the box is ofstandard size (e.g., 12 inch by 12 inch by 6 inch deep) with an emptyweight of about 15-35 lbs. The front cover is hinged and lockable witheither a keyless screw lock or a keyed secure tumbler tube lock. Araised removable mounting plate (e.g., 11 inches by 11 inches) ispre-mounted to the back of the box for easier mounting of a main circuitboard and generally has at least one insulation layer of a suitablematerial, such as an aerogel. The removal mounting plate is generallymade of a hardened metal, such as steel. The insulation layer is sizedto the box (e.g., 12 inch×12 inch×6 mm) and placed in the interior ofthe box between the back plate and the raised removable mounting plate.Holes may be prepared in the insulation layer to align with the mountingstud positions located on the back exterior of the junction box.

Mounting of the circuit board is typically performed using non-thermalconducting mounts (e.g., ⅜ inch nylon stand-offs). The main circuitboard as shown in FIG. 7 is fastened to the stand-off mounts on theremovable mounting plate by either of two methods. In a first method,screws are used, typically ¼″×#40 screws. This method is preferred ifthe main circuit board is the only component inside the SACA junctionbox. In an alternative method, stand-off extenders (e.g., nylon #40)with a threaded screw end (to fasten down the main circuit board) and athreaded compatible socket end are used. This method is preferred whenaccepting and attaching a second board, referred to herein as amezzanine board.

A mezzanine board, when provided with the junction box system, is eithera single board or a dual stacked hoard. For dual stacking, the upperboard is separated from the lower board by about an inch usingstand-offs generally made of nylon; only the lower board is screwfastened into place. Separation by way of a stand-off extension betweenboards ensures uniform separation and adequate clearance from thejunction box front cover when closed.

The mezzanine board supports a multi-fiber mini cable race system whenmultiple fiber channels are bundled in a SAGA cable assembly segmentbeyond the conventional standard configuration. The mini cable racesystem as exemplified in FIG. 7 allows for direct thermal splicing ofunused fiber channels within the current configuration into a passivepass-through mode. Incoming cables are thus allowed to enter on one sideof the mini cable race system and spiral in; outgoing cables entering ona second side spiral in and meet their equivalent channel in the centersection at which point there is thermal splicing. The mini cable racesystem allows selected channels (typically 3 maximum) to be drop splicedonto jumper patch cables with pre-mounted male plugs suitable for directplug-in to the main circuit board media converters. Re-amplification ofone or more of the selected channels is thereby accomplished, allowinglimitless lengths of the SAGA cable assembly system to be created, wellbeyond the conventional length for multi-mode optical fibers.

The same mezzanine board or an additional one may be used to support athermal cooling system that may optionally be included in the junctionbox. The thermal cooling system is a liquid cooling system used toexhaust thermal buildup caused by internal components or by heat arisingfrom an external source, such as a fire. The thermal cooling systemdepicted in FIG. 4 uses one or a number of sensor thermal couples 41attached to hot chips and cooling tubes 42 inserted into the coupledcable segments (incoming and outgoing). An on-board CPU monitorstemperature within the box and is activated at a pre-determinedtemperature. The CPU is coupled to directional valves that are activatedat the pre-determined temperature to allow fluid flow. The systemincludes a pump 43, reservoir 44, thermal pickup links 45 mounted on themain circuit board, a flow coupler 46 and as flow valve solenoid 47.Electronics for the pump and valve portions are typically located on themezzanine board. Connecting tubes 48 in the system carrying coolingfluid are generally soft flexible tubing, such as silicon tubing. Thethermal cooling system transfers heat smartly outside the box ratherthan allow it to buildup and damage internal electronics within thejunction box.

Referring now to the main circuit board a representative circuit diagramis depicted in FIG. 8A. The board is a collection of plug-in modules anda carrier mother board for signal and power distribution as shown inFIG. 3. Modules include a power supply module 32 and processor module 34that is customized for each junction box depending on desiredselections. As plug-ins, the modules offer easy access for replacementand/or upgrades, particularly on location. Additional components of ajunction box may include router 36 previously described and optional UWBradio 38 and/or antenna 39.

Power leads from the incoming and outgoing cable segments are fused tothe power block on the main circuit board. Power at 110 Volts is tappedoff and routed to the step down DC power supply module. A polarizedheader type connector in the same area as the AC input for the motherboard allows for connection to an on board UPS that is connected to astorage cell mounted against the outer wall of the junction box. A base5 Volt power is run to any of the attached modules from the power supplymodule, there is also signal in and out pathways provided tointerconnect the modules eliminating the need for any loose patch cordsfor module to module connections. Status circuits from each module arerouted back to the processor module for fault and operations monitoringand control.

The junction box mother board power supply module 81 provides two DCoutput voltages of 5 Volt and 12 Volt and the input supply circuit isdesigned as a UPS system 82 deriving its power from an on board battery83 (e.g., lithium polymer cell, rechargeable when desired) as back-upwhen either AC power 84 is no longer available (see FIG. 8B, lowerleft). Routing of DC supply voltage is through lands on the junction boxmother board. The on board battery is designed to provide the contentsof the junction box with sufficient power for 4 continuous hours of fulloperation or 12 standby hours. The battery is typically held against theside wall of the inside of the junction box accessed by removable clips.

The on board processor includes a separate controller system (herein“CS” identified as 85 in FIG. 8B lower left) that comprises amicroprocessor circuitry and a downloadable and updateable program andoperating system for directing and/or monitoring operations within thejunction box. The controller system does not depend on an operator foron-board processor operations and provides status as well as alerts withrespect to the junction box. The CS is depicted in one embodiment asFIG. 8 and is a software configurable device that prioritizes a seriesof alternatives should the primary objective (path) become unavailable,thereby it ensures that the communication system described herein isfault tolerant and continuous for both normal operations and foremergency communication.

The CS is a self contained self powered device, having its own integralUPS and an additional conventional 110 Volts AC power source; it is notdependent on a main supply of power to remain operational. It has areverse destination powered sharing capability. It carries its ownbattery backup system when there is a power outage. The battery backupsystem expands the current or wattage handling capability of the DC toAC conversion system; during non-emergency periods, the battery back-upsystem maintains the normal operating power and is fully charged.

The CS cabinet depicted in FIG. 9 is approximately 24 inch deep by 44inch wide by 12 high of stainless steel construction with a right anglehinged top and front locking side as the opening cover to the cabinet.Alternate arrangements are equally suitable. The heavy gauge cabinet(preferably stainless steel) is to withstand corrosion in anyenvironment and to provide maximum mechanical protection to the internalcontents. Its interior is outfitted with an insulation layer, thematerial made of aerogel. The cabinet is securely grounded to a buildingpower supply ground circuit. The cabinet is kept off surface withoutrequiring physical means for securing it. Two front to back right-angledrunners are welded to the bottom of the cabinet.

The metal foldings depicted in FIG. 9 and subsequent welding means thecabinet is a secure vessel for protecting the internal contents. A rightangle folded top lid is edge folded and water seal matched with thelower portion of the cabinet. A tubular type cam lock provides a securelocking of the folded top lid to the lower bottom portion.

The CS being is tamper resistant with multiple sensors mounted on andwithin the cabinet to sense any unauthorized tampering. Attempts atmoving the cabinet or opening will trigger an output signal from theC.S. A similar system is in place for the SACA cables and junction boxwhich are also continuity monitored.

The CS also acts as a head end controller for a satellite dish (e.g.,SU); it may use KU band equipment or KA band equipment. Line loss fronta satellite low noise block (LNB) converters to a controller modem isminimized by mounting the controller modem within a CS cabinet (e.g.,adjacent to or under the satellite dish). The coaxial signal and powerleads are long enough for impedance matching and to facilitate easyrelocation of the satellite dish (e.g., SU) to maintain clear site angleto the respective satellites that the dish is assigned to. In addition,an optional dual LNB and LNA triage unit may be included with the CS forautomated swap out if there is component failure.

Satellite communications into the CS system are maintained regardless ofterrestrial power problems because the dish components are powered bythe onboard UPS-supported CS cabinet. The CS also includes a smartcontroller that automates orbital satellite location and communicationwhich includes a self-aligning software package provided by a suitableprovider (e.g., Phase Array Antenna by AIL EDO Industries). The CSsystem interfaces with either a gimbaled mount system disclosed inco-pending U.S. patent application Ser. No. 12/020,269 or with amotorized dish assembly similar. Control of the gimbaled mount system orother motorized assembly is through CS, mounted within the cabinet asdepicted in FIG. 8B. Data connection from the controller/modem to themulti-port switch/VPN router is powered by the UPS system. Thus, asdescribed, is a fault tolerant communications system not dependent onterrestrial services for operation.

Operation of the CS system are handled by a computer such as onepositioned as a command console (see FIG. 10) using a scripting languageand remote access management made possible by a specially authorizedremote terminal. For uniformity, a SACA junction box circuit board isused in the command console and a SACA junction box circuit board isused as a sending terminus in the CS.

The CS onboard VPN router is cross connected via a connection, such asthat provided by an Ethernet 10/100 Mb/s Cat: 5e connection, to the headend of the SACA cable exemplified in FIG. 8B through on-board junctionbox mother board media converters. The VPN router has multiple outputports that may be configured to capture data traffic on a specificVirtual Private Network (VPN) channels or ports and is able to dedicatesuch traffic to a specific Ethernet port. Specific data traffic may thenbe directed through an Ethernet patch line to an appropriate/designatedfiber channel media converter. The dedicated VPN when becomes privatizedover a channel B or channel C fiber and subsequently delivers the routeddestination, terminating eventually in one or more media converterswhere it is translated back to electrical Ethernet feed and begins itsprogrammed use.

The use of optical regenerating media converters within the SACA systemcombined with the fiber optic transport provided by the cable assemblymeans data traffic originating with either a SU or another source (e.g.,microwave digital radio link) and managed by the CS system may berelayed to near infinite distances as defined by the SACA cable assemblyand junction boxes. As such, the CS connects to the SACA cable assemblythrough fiber optics and power circuits and subsequently through a selfgenerated solicitation system comprising of a DHCP server within the CSthat solicits each connected junction box as each cable segment comesonline. The system as described provides a single secure network anddoes not require authorization from a Building Area Network (BAN).

CS uses the mother board from the junction box for media conversion andhence data transporting, as well as being a primary power source. The CSwill typically require a dedicated 110 Volts AC power source with aminimum delivered current of 30 Amperes at the power distribution panelterminating point. The 30 Ampere power source is the primary powersource for the CS and SACA cable assembly,

The router described previously is preferably an addressable dual WANrouter and is combined with an addressable microprocessor circuit. Thecombination provide status of the health and functionality at eachjunction box which is relayed to a CS main processor. Any alert isrelayed immediately by the CS to a central monitor.

Each CS cabinet is also outfitted with a transceiver and an externalSMA-type cable connected high gain antenna (e.g., a UWB parabolic highgain fractal antenna) as depicted in FIG. 11. The transceiver isprovided with a capability of switching from International TelephoneUnion standards and IEEE standard 802.15.4 restricted power to a higherpower 802.15.3 restricted standard (i.e., one limited within the U.S.under FCC rulings to military and emergency communications use only).The increase in power and subsequent range of the UWB (UWB) signalallows the dispersion range with wall penetrating capability to reachapproximately three miles, such as when a governmental authoritydeclares an emergency.

A WiFi ITU/IEEE 802.11a/b/g antenna router device may optionally beattached to an output port on one or more junction boxes. Placement issuch that their operation is maximized. With the added router device, aCS may receive communications and route them through the cable assemblyand junction box (either via channels A, B or C) to a specific WiFi orWiMAX device. For example, law enforcement information may be relayedthrough the CS to a breakout point where the high-gain long range WiFior WiMAX antennas are positioned to securely send a signal to a nearbyemergency vehicle or station or individual capable of picking up thecommunication.

A cable raceway termination as previously described is also installed inthe CS cabinet for entry of fiber optic cables from the SACA cableassembly into the cabinet (e.g., typically mounted as a mezzanine boardabove the SACA junction box main motherboard). Not all fiber channelsneed to be cross connected to communications sources at this point, somemay bypass and be routed straight through the junction box, therebymaintaining segment to segment functionality of the SACA system.

As described herein, the CS system also incorporates keyless encryptionof both incoming and outgoing data readily available from one or moreproviders. Encryption helps ensure the secure transport of agnostic dataover the entire communications system. Encryption is typically set tosecurity level of Category 5, which has also been referred to as OrangeBook level B1 standard.

The CS may be used with multiple communications channels enablingsimultaneous performance one or more end purposes. In one example, CS isused to regulate emergency and/or remote access signals throughsatellite while simultaneously regulating microwave relayed broadbandinternet access running from roof top to roof top and also deliveringcommunications signal (via the SACA system) to numerous end-users withinone or more buildings. Such flexibility to make broadband transportavailable to multiple and different end users earns the system describedherein as the ultimate agnostic transport layer.

Referring back to the junction box, the processor as previouslydescribed may be incorporated prior to or after installation at a fieldlocation. The processor is thus a replaceable module that plugs into thejunction box main mother board. Power and signal routing are shared aswell as distributed on the main mother board. Simple logic as well ascomplex functions may be programmed into the junction box processor;status of the box may be monitored by a WEB enabled interface allowingfull graphical status monitoring of all junction box functions.

Each junction box has the ability to distribute three channels (see FIG.8A). Channel A is primarily for emergency communications and securitypurposes and has been designed with fault tolerance and a backupwireless connection circuit. Channel B is an in-house data channel,typically used to distribute broadband services. Channel B traffic mayalso include display screens, sensor camera input, and data entryequipment, as examples. When channel B includes display information, anadditional component may be added to the junction box for wirelessbroadband connectivity from a currently addressed junction box to adedicated display screen (e.g., digital, plasma, HD, LCD) using awireless UWB dedicated DATA module as shown in FIG. 5.

When broadband wireless delivery is needed from a junction box to aremote delivery site, such as large screen display, a channel B mediaconverter may be directed to a Mercury™ data delivery module, whichincludes UWB 802.15.4 data delivery complying with UWB technology andrestricted to ITU/FCC 802.15.4 (provided by TZero Corporation). As anexample, high-speed broadband data is targeted or addressed to adiscreet TCPIP addressed UWB 802.15.4 module capable of transmitting upto 800 megabytes per second over a distance of up to 80 meters (250ft.).

Junction box channel C is left open to the extent that signalstransmitted along any number SACA cable segments must enter a mediaconverter and exit a media converter therefore a standardized format of10/100 Mb/s is required unless a segment to segment conversion is doneto an alternate data rate or format.

The junction box when equipped with one or more mezzanine boards maysupport both an incoming 10/100 Mb/s Ethernet optical feed as well as anoutgoing alternate data format converter, thereby leaving the remainderof the contiguous sections available for (alternate) usage.

The junction box uses optical media converters of an improved design(depicted in FIG. 8A; exemplified in FIG. 12) to convert incoming andoutgoing fiber optic signals to conventional TCPIP copper signals. Theonboard media converters also facilitate third party and/or externalattachments to the junction box thereby providing an agnostic transportsystem over a common wiring facility. Junction box media converters arestandardized at 10/100 Mb/s TCP/IP data feed terminating in RJ-45standard connectors as defined by the IEEE and ITU. Junction box mediaconverters may be upgraded, changed or added to alter the primary dataformat from 10/100 Mb/s Ethernet to Asynchronous Transfer Mode, or anyother fiber compatible transport methodology. The only controllingfactor is that the starting point of the segment and the end deliverypoint as well as every channel C junction point between the startingpoint and the end delivery point must be the same data transmissionformat. Access points between the starting point and end delivery pointmay allow entry for sharing access to channel C data.

In the example of wired TCPIP signal, the signal in channel A is firstrouted to a dual port wireless AIG router. Simultaneously link and dataindicator circuits are displayed on status LED lamps (for visualindication of function) and routed to the junction box processor. Thejunction box media converters are monitored by the junction boxprocessor, constantly ensuring proper link activity on allcommunications channels. Failure of a link indicator signifies the onboard processor to instruct alternative backup circuits to maintainconnectivity with its assigned connections.

A junction box circuit protection system allows the on board junctionbox processor to reassign fiber optic cable communications to analternate path through an onboard UWB or a WiFi wireless device shouldthe cable fail. The box is also designed to simultaneously send an alertmessage to the CS and command console. For example, should data trafficon channel A (primary channel) fail, UWB signals come into play. Foroperation, a dual port wireless router switch (e.g., A/B/G protocol10/100 speed router switch) is incorporated onto the main mother boardof the junction box. The dual port feature allows for a primary path WANside to be connected to the pass through fiber optic channel A. Asecondary WAN port is also routed electrically to the data side of theUWB radio. Failure at any time of the higher speed primary WAN channelcauses the router to automatically switch data to the UVVB radio. Theonboard WiFi circuit in the router may be directed as a traffic port forchannel A information such as remote wireless sensors or wireless camerainputs.

Just as the SACA cable may bundled with a multi-fiber cable, so will thejunction box be equipped with multi-fiber handling capacity. Whenneeded, this is performed by installing the appropriate Mezzanine boardwith cable race and splice tray handling. Drop channels to a maximum of3 must be broken out in the splice tray and properly terminated (e.g.,to patch cables) for access to the onboard media converters on the mainmotherboard. The same fiber channel (and number) coming into a mediaconverter must also exit and rejoin the multi-fiber cable to maintain acontiguous delivery system.

Channel A traffic flowing through a normal fiber optic channel in thecable segment is directed by the channel A media converter to the dualport router onboard each junction box. Software (up loadable firmware)will route traffic first to a primary link fiber channel, only fallingback to the secondary port when data cannot flow on the primary circuit.The operating firmware allows a secondary TCP/IP addressing to beassigned to the secondary port so a second access port to router andcorresponding fiber transport layer are established. The dual portrouter has both four+one ports of 10/100 Mb/s Ethernet and supports upto 254 wireless addresses with WEP and WPA authentication and MACaddress security.

The secondary WAN port is connected to the data input side of an onboard transceiver module which shares features with a dual port routerallows the secondary WAN port to become an addressable LAN port, therebyproviding dual functionality to the transceiver. As long as the primaryWAN Port is active and not experiencing any data flow problems, then thetransceiver attached to the secondary WAN Port becomes a bi-static ormono-static radar device.

An addition plug-in card on the junction box is an EWT transmitter, asshown in FIG. 5, referred to a Mercury Transceiver. The card plugs intoa mating connector located inside the junction box. The EWT unit relaysspecific information addressed to it, as WiFi or UWB transmissions at apre-selectable power level. At low power setting or normal operation,the UWB transmission complies with FCC and IEEE/ITU 802.15.4 standardsfor in building use. The addressing capability of the junction boxallows for individual power levels to be adjusted at the output port andthe EWT facilitates not only a corresponding change frequency bandwidthbut is also capable of ramping up its power output, which is controlledby an automatic gain control (AGC) or power stepping circuit.

Another feature of the EWT plug-in device is an optional antennadiversity module that may be added. The antenna module supports up tofour antennas for each junction box location. In one form, the EWTextension is four UWB transmitters plugging into a common addressablefeed point on the junction box. In this case only the digital Ethernettype signal and power is fed through the parallel interface to drive upto four UWB transmission modules, each with their own position sensingfractal antenna unit or high gain directional antenna (depicted in FIG.5). Such an application is preferably used for large horizontalstructures. Those of skill in the art will understand that the plug-indevice may be deployed every 4 to 10 floors, depending upon the type ofRF communication being used. For longer distances in non FCC compliantareas, a high gain directional parabolic fractal antenna may be used tomaximize distance and signal strength. This type of antenna has provento increase range at low power and high power settings from 50 and 100feet normal respectively, to 500 and 1000 feet outdoors.

As described herein, controlled manufacturing steps and pre-selectedfeatures together provide the communications system described hereinwith both mechanical and thermal protection to not only survive physicalchallenges but to also offer a system with continuous power andcommunication, particularly to first responders. Within a singlecommunications assembly, the system described herein will transmitunlimited amounts of information using multiple types of operations thatare fault tolerant and secure.

Data handling capabilities have been expanded with the system describedherein. By combining fiber optics, the quantity of data has increasedexponentially and the communication range has been extended well beyondthe 300 foot limit previously encountered with systems relying oncopper. Radio frequency additions extend the reach to wireless devices adistance away from a distribution point.

Modular lengths or segments of cable may be extended to unlimitedlengths. Through the use of standardized cable fittings for both outercable attachments as well as individual power and transmission lineswithin the cable, the capabilities of this system are extended andincorporate a plug and play method to commercial wiring. Cable segmentsremain independently addressable and controllable in view of theversatile junction box. In addition, having a fiber optic repeater andconverter for each optical channel, any data circuit may easily beaccessed with standard Ethernet plug fitting, making the use, servicingand adoption of the entire system easy and cost efficient.

Independent management processor systems within each junction box asdescribed herein not only supply the health status of each junction boxbut also control the distribution and functioning of auxiliaryoperations with the scope of the junction box. The onboard UPS processorcircuit manages security, communications, functionality and self healthof the junction box and is coordinated with an external controllerdevice. Pre-programmed processes and updates, managed remotely, areperformed continuously on each junction box to ensure performance.

The improved multifunctional motherboard design with plug-in modules asdescribed herein facilitates functionality and servicing of eachjunction box once installed. The improved design is also suited tosupport multiple fiber optic channel routings as well as multiple radiofrequency transmission channels.

The junction box herein includes a unique wireless data communicationsthat may penetrate obstructions such as walls or debris may also be usedfor extreme broadband transmission applications and yet further, uponcommand, be used with a tagged or tag-less tracking system. Hence, thejunction box herein is a fully programmable device for both normalbroadband communications, human tagged and tag-less tracking device andsupplies emergency first responder type communication in a time ofdisaster. In addition, the junctions box includes a unique andintelligent cooling method that reduces internal heat and expel the heatfrom the box, thereby alleviating damage to the electronics.

The junction box terminates a cable conducting segment (optical andelectrical components) and providing connectivity as well as mating tothe next cable segment in the system. As described previously, opticalconnectors are chosen to reduce space requirements as well as signalloss. The junction box junctions each power sections of the SAGAassembly system while tapping off 110 volts as required and may convertpower to a low voltage DC for use with additional components, such as anoptical amplifiers, address decoder, router, RF linear components, andthe like, Hence, a junction box is capable of amplifying (optically andlinearly), digital routing and decoding.

According to one or more embodiments, a SACA system includes serialtransmission cables linking two separate control points, such as a SUand a corresponding command console, while also allowing segmentedsections of the cable at fixed and predefined intervals to be used forretransmission through RF or digital signals sent to third party(non-directly associated) devices.

A SACA system comprises a power conduit and a reference ground system,along with one or more connectivity routes between a SU and a commandconsole. Optical signal connectivity in the system prevents line lossand/or length limitations associated with TCP/IP (e.g., overconventional CAT-5 or CAT-6 wired cabled connections). A secondarysignal buss (repeater) periodically connects with an addressablejunction box that, in turn, may interconnect to one or more externaldevices for the purpose of retransmitting data or bridging a gap whenone occurs between two associated SACA junction boxes.

The repeater periodically regenerates signals to ensure that they reachtheir intended destination(s). With a SACA communication systemdescribed herein, information in any form is repeated and carried on toa central monitor communications system and also transmitted to one ormore local positions. In example, an emergency communication is relayednot only to the central monitor but also to local emergency personnelhaving RF equipment. With this system problems such as those experiencedin recent disasters will not occur.

More specifically, with the system described an analog RF signals thatis normally inhibited by physical structures is introduced through thecable assembly to a command console from antenna output of any portablewireless communicator. By removing the antenna from a handheld deviceand connecting the cable assembly described herein, a RF signal isinjected into the cable assembly and through software control isaccessible from the command console, and is periodically repeated atmultiple junction box points. Addressable coaxial switches, along with alinear amplifier, facilitate analog RF processing within the SACAjunction box. Linear amplifiers within the junction box device not onlyrepeat and pass along information to the next serial junction box, butalso connect information to a local antenna when one is attached to thejunction box so that the signal radiates from the antenna.

While specific alternatives to steps of the invention have beendescribed herein, additional alternatives not specifically disclosed butknown in the art are intended to fall within the scope of the invention.Thus, it is understood that other applications of the present inventionwill be apparent to those skilled in the art upon reading the describedembodiment and after consideration of the appended claims and drawing.

What is claimed:
 1. A communication systems providing a fault-tolerantcommunications path for narrow and broad band communication comprising:one or more self-powered satellite units each providing signalinformation to at least one command console through a segmented cableassembly system; a central station that receives signal information fromthe at least one command console and relays signal information back tothe command console wirelessly and via the segmented cable assemblysystem.
 2. The communication system of claim 1, wherein the segmentedcable assembly system is powered by a controller outfitted with atransceiver and an external high gain antenna.
 3. The communicationsystem of claim 1, wherein the segmented cable assembly system includesa repeater.
 4. The communications system of claim 1, wherein the cableassembly includes a UWB radio and antenna.
 5. A cable assemblycomprising one or more fixed length cable segments, each segment linkedto a junction box having a repeater system to extend a signalcommunications range significantly further than 3000 feet.
 6. The cableassembly of claim 5, wherein the each segment includes a metal casingand core bundle wrapped with an aerogel material.
 7. The cable assemblyof claim 5, wherein each segment includes a stress release system, eachsegment configured for 2600 pounds of longitudinal force.
 8. The cableassembly of claim 5, wherein each segment will re-broadcast a signalselected from the group consisting of UWB, WiFi and RF.
 9. The cableassembly of claim 5, wherein the cable assembly has no vertical orhorizontal constraints.
 10. The cable assembly of claim 5, wherein eachsegment will withstand temperatures in excess of current plenum andriser wiring standards.
 11. The cable assembly of claim 5, wherein thejunction box has plug-in circuit board.
 12. The cable assembly of claim5, wherein the junction box includes a raceway system to drop splicefiber optic channels for direct plug-in to one or more main circuithoard media converters.
 13. The cable assembly of claim 5, wherein thejunction box includes a thermal cooling system operable with an on-boardCPU to prevent overheating and failure.
 14. The cable assembly of claim5, wherein the junction box includes two DC output voltages of 5 Voltand 12 Volt operable with a UPS system deriving its power from an onboard battery.
 14. The cable assembly of claim 5, wherein the junctionbox is controlled by a separate controller.
 15. A cable assemblycomprising: one or more fixed length cable segments, each segmentcapable of withstanding temperatures in excess of current plenum andriser wiring standards, wherein each segment includes a high gauge metalcasing and a core bundle wrapped with a heat resistant aerogel material16. The cable assembly of claim 15, wherein the core bundle includes oneor more power conductors, one or more multi-mode fiber-optic datachannels, a coaxial cable 40 and a high strength stress cable.
 17. Acontroller comprising: a transceiver; an external SMA-type cableconnected high gain
 18. The controller of claim 17, wherein thetransceiver is capable of switching IEEE 802.15.4 to 802.15.3.
 19. Thecontroller of claim 17, wherein the signals from the controllerpenetrate walls.
 20. The controller of claim 17, wherein the controlleris operable with an antenna router device for transmitting signals to awireless device.